Metal roofing



Nov. 19, 1968 ANDERSON ETAL 3,411,259

METAL ROOFING 2 Sheets-Sheet 1 Filed June 9, 1966 1 INVENTORS C 1 IVARE. ANDERSON 3 WILLIAM J. HEIDRICH TTORNEYS NOV. 19, 1968 ANDERSON ET ALMETAL ROOF ING 2 Sheets-Sheet 2 Filed June 9. 1966 ,INVENTORS IVAR E.ANDERSON WILLIAM J. HEIDRICH wxsw A ORNEYS United States Patent3,411,259 METAL ROOFING Ivar E. Anderson and William J. Heidrich, Rome,N.Y., assignors to Revere Copper and Brass Incorporated, Rome, N.Y., acorporation of Maryland Filed June 9, 1966, Ser. No. 556,449 2 Claims.(Cl. 52-531) AESSTRACT OF THE DISCLOSURE In a sheet metal roofingstructure featuring shingle-like courses, the ends of each courseterminate in half of a groove-like depression and a flashing pan withupturned water seal side lips and a bottom backing flange spans theunderside of each joint between the aforementioned ends of the metalsheet.

This invention relates to roofing construction, and more particularly tometal roofing comprising a plurality of shingle-like metal sheets thatform a weather-tight outer sheath or layer when secured to the roofsubstructure.

It has heretofore been proposed that shingle-like metal sheets beemployed as a roofing material in the construction of attractive,lightweight, fireproof and weather resistant roofs. In such roofingconstructions the shinglelike metal sheets are usually laid side by sidein a plurality of horizontally extending and vertically overlappingcourses or rows of sheets. In order to provide a weathertight sealbetween the metal sheets in each horizontal row of sheets, the adjacentend edges of adjoining metal sheets are usually formed with overlappingand interlocking sealing flanges which are adapted to prevent rain waterand the like from penetrating through the joint to the underlyingroofing substructure. In like manner, the bottom edges of the metalsheets in each horizontal row are formed with downwardly extendinglocking flanges which overlap and interlock with upwardly extendinglocking flanges formed adjacent the upper longitudinal edge of the metalsheets in the horizontal row of such Sheets positioned directlytherebelow. One of the principal limitations of this type of metalroofing construction is that the individual metal sheets must be laid onthe roofing substructure in a fixed order (usually from left to rightand from bottom row to top row) due to the need for overlapping andmechanically interlocking the adjacent end edges of the metal sheets ineach horizontal row and for overlapping and interlocking the adjacentlongitudinal edges of the vertically overlapping rows of metal sheets.In order to overcome the limitation imposed by the need for horizontaland vertical overlapping and interlocking of the metal sheets, it hasbeen proposed that the .adjacent end edges of the adjoining metal sheetsin the horizontal rows of sheets abut each other, rather than interlockwith each other, so that the individual metal sheets in each horizontalrow can be laid on the roofing substructure at either end of a metalsheet already fastened to the roof. However, although this modificationof the aforesaid type of roofing construction permits much greaterflexibility in the order in which the metal sheets can be laid on theroofing substructure, serious difiiculties have been encountered inmaking the butt joint of the adjoining metal sheets weather-tight.

We have now devised a significant improvement in metal roofingconstruction which overcomes the structural and functional disadvantagesof the prior metal roofs hereinbefore referred to. The metal roofing ofour in vention is readily applied to conventional roofing substructureswithout the need for overlapping or interlocking of adjoining metalsheets in the same horizontal row of sheets while providing a strong andweather-tight metal "ice outer sheath for the roof. Our improved roofingconstruction comprises a plurality of shingle-like metal sheets laid onthe roofing substructure in a plurality of vertically overlappinghorizontal rows or courses of abutting sheets. The abutting edges ofadjoining metal sheets are turned downwardly so that they lie in closeproximity to a uniquely designed metal flashing pan which is disposedtherebeneath. The metal flashing pan collects rain water and the likewhich may penetrate between the adjacent edges of adjoining metal sheetsand delivers this water to the upper surface of the metal sheets of thehorizontal row of sheets disposed directly therebelow. Moreover, themetal sheets and metal flashing pans of our roofing constructioncooperate to provide a strong and weather-tight metal sheath that isresistant to high winds and other external forces which cause priorroofs of this type to leak.

Specifically, each of the shingle-like metal sheets of the roofingconstruction of our invention are formed with a downwardly turned lowerlocking flange along the lower longitudinal edge of the metal sheet andwith an upwardly turned upper locking flange adjacent but spacedslightly below the upper longitudinal edge of the metal sheet' Inaddition, each metal sheet is formed with at least two, and preferablythree or more, vertically disposed grooves extending from a pointslightly above the downwardly turned lower locking flange of the metalsheet to a point slightly below the upwardly turned upper locking flangeof the metal sheet. One of the vertically disposed grooves is located ateach end of the metal sheet with the vertical edge of the metal sheet atthat end of the sheet terminating at the bottom of the groove so thatboth end edges of each metal sheet will lie in close proximity to theunderlying roofing substructure on which the sheet is ultimately laid.Moreover, each flashing pan disposed beneath the abutting end edges ofadjoining metal sheets is formed with a downwardly turned locking flangeat the lower edge, and with an upwardly turned lip member along eachvertical end edge, of the flashing pan. The two upwardly turned lipmembers extend from the upper edge of the flashing pan to a pointlocated above the locking flange of the flashing pan a distance equal toat least one-half but not more than the full distance that the upperlocking flange of one of the metal sheets is spaced below the upper edgeof said metal sheet.

When the individual metal sheets of our invention are secured to aroofing substructure in a plurality of vertically overlapping horizontalrows of metal sheets, the downwardly turned abutting end edges ofadjoining metal sheets in each horizontal row lie in close proximity tothe upper surface of the metal flashing pan disposed therebeneath,thereby substantially reducing the likelihood of water penetratingthrough the juncture of the two sheets. Moreover, any water that maypenetrate the abutting end edges of adjoining metal sheets is collectedby the flashing pan which delivers the water to the upper surface of themetal sheet lying directly therebelow. In addition, the downwardlyturned end edges of the metal sheets stiffen the sheets and make themmore rigid, thereby substantially eliminating the possibility that theedges of the metal sheets might be lifted or bowed upwardly by alongitudinally directed wind or other external force.

The improvement in metal roofing construction of our invention will bebetter understood from the following description thereof taken inconjunction with the accompanying drawings of which:

' FIG. 1 is a fragmentary perspective view, partly broken away, of theroofing construction embodying our invention showing the trough-likejuncture of two pitched roof sections,

FIG. 2 is a perspective view, partly broken away, of the roofingconstruction of our invention showing the ridge-like juncture of twopitched roof sections,

FIG. 3 is a fragmentary perspective view along section line 3-3 of FIG.1 showing the preferred locking flange construction employed tointerlock the vertically overlapping metal sheets,

FIG. 4 is a non-perspective view similar to FIG. 3 showing amodification of the locking flange construction employed to interlockthe vertically overlapping metal sheets,

FIG. 5 is a perspective view of one of the novel flashing pans employedin our roofing construction,

FIG. 6 is a sectional view along line 66 of FIG. 2 showing the manner inwhich flashing pan underlies and supports the abutting end edges ofadjacent metal sheets,

FIG. 7 is a sectional view along line 77 of FIG. 2 showing the manner inwhich the flashing pan and the overlying metal sheet interlock with theupper locking flange of the metal sheet disposed directly therebelow,

FIG. 8 is a sectional view of an alternative method of making aweather-tight joint at the valley formed by two pitched roof sections,and

FIG. 9 is a perspective view of one of the interlocking ridge covermembers employed in the roofing construction of our invention.

As shown best in FIGS. 1 and 2 of the drawings, the general type ofroofing construction to which our invention relates comprises aplurality of horizontal rows or courses 10a, 10b, 100, etc. ofshingle-like metal sheets 11 which overlap and interlock with the metalsheets of the course disposed directly above or directly below. Theshingle-like metal sheets 11 are secured (for example, by nailing withroofing nails) to the planar roofing substructure which comprises,usually, a layer of wooden sheathing material 12 (such as plywood or thelike) and a layer of waterproofing material 13 (such as tarred roofingpaper or the like).

Each shingle-like metal sheet 11 is provided with an upwardly turnedupper locking flange 15 adjacent but spaced slightly below the upperlongitudinal edge 16 of the metal sheet, and with a downwardly turnedlower locking flange 17 adjacent the lower longitudinal edge of themetal sheet. The upwardly turned upper locking flange 15 isadvantageously formed by a double reverse or S bend integrally formed inthe metal sheet 11 adjacent the top edge 16 thereof as shown best inFIG. 3. Alternatively, the upper locking flange may comprise a separateflange member 15a that is secured, for example by welding, to the outersurface of the metal sheet 11 adjacent the upper longitudinal edge 16thereof as shown in FIG. 4. The upwardly turned upper locking flange 15of the shingle-like metal sheets 11 in one of the horizontal courses ofsheets engages and interlocks with the downwardly turned lower lockingflanges 17 of the metal sheets 11 in the horizontal course 10 directlythereabove in a manner well known in the art.

Each shingle-like metal sheet 11 is formed with at least two, andusually three or more, vertically disposed depressed grooves 19 whichextend from a point slightly above the lower locking flange 17 of themetal sheet to a point slightly below the upper locking flange 15 of themetal sheet. One of the vertically disposed depressed grooves 19 islocated at the vertical edge 20 at each end of each metal sheet, the endedges 20 of the metal sheet being located at the bottom of the depressedgrooves 19 so that the end edges of the metal sheet lie in closeproximity to the underlying roofing substructure as shown best in FIG. 6of the drawing. The metal sheets 11 are assembled side by side in eachhorizontal row 10 with the end edges 20 of adjacent metal sheets in eachrow abutting but not overlapping as also shown most clearly in FIG. 6.

The butt joint of the end edges 20 of adjacent metal sheets 11 is not,by itself, weather-proof or water-tight. To provide a water-tight andweather-proof joint, a specially designed metal flashing pan 22 isdisposed directly beneath the abutting edges of adjoining metal sheets11.

The metal flashing pan 22 is provided with a downwardly turned lockingflange 23 at the lower end edge thereof that is adapted to engage theupwardly turned upper locking flange 15 of a metal sheet 11 disposeddirectly therebeneath. This feature of our flashing pan construction isclearly shown in FIGS. 1, 5 and 7 of the drawings. An upwardly turnedWater seal lip member 24 is provided along each vertical edge of theflashing pan 22, the upwardly turned lip members 24 being adapted notonly to prevent rain water and the like from flowing onto the roofingsubstructure but also to contact and support the undersurface of themetal sheets 11 under which the flashing pan is disposed as shown inFIG. 6. The lower end 25 of each of the water seal lip members 24terminates at a point located slightly above the downwardly turnedlocking flange 23 of the flashing pan 22. The distance above the lowerlocking flange 23 that the lip members 24 terminate is equal to at leastone-halt, but is not greater than, the distance that the upper lockingflange 15 of each metal sheet 11 is spaced below the upper longitudinaledge 16 of said metal sheet. This distance is critical because theupwardly turned water seal lip members 24 must extend downwardlysutficiently far so that they overlie the upper longitudinal edge 16 ofthe metal sheet 11 disposed directly therebeneath, whereby rain waterand the like collected by the flashing pan will be delivered onto theupper surface of said metal sheet 11. At the same time, the lip members24 must not extend downwardly so far that they interfere with theengagement and interlocking of the downwardly turned lower lockingflange 17 of the overlying metal sheet 11 with the upwardly turned upperlocking flange 15 of the metal sheet positioned therebelow. This featureof our new roofing construction is clearly shown in FIG. 7 of thedrawing.

The roofing construction of our invention is applied to a substantiallyplanar roofing substructure by first nailing or otherwise afiixing ametal starting strip 27 to the lower edge or eave 28 of the roof asshown in FIGS. 1 and 2. In addition, V-shaped metal flashing 29 isapplied to the trough-like joints formed where two pitched roof sectionscome together as also shown in FIG. 1. The shingle-like metal sheets 11and the metal flashing pans 22 of the first or lowermost horizontalcourse 10a of the metal roofing are then applied to the planar roofingsubstructure by first securing the metal flashing pans 22 to thesubstructure at appropriate intervals (that is, whereever it isanticipated that two adjoining metal sheets 11 will abut each other) andthen securing the metal sheets 11 in abutting relationship to theroofing substructure. The metal flashing pans 22 of the first orlowermost course 10a are secured to the roofing substructure by engagingthe downwardly turned locking flange 23 at the lower end thereof withthe metal starting strip 27 followed by nailing the upper longitudinaledge of the flashing pan to the substructure. Similarly, the metalsheets 11 of the lowermost course 10a are secured to the roofingsubstructure by first engaging the downwardly turned lower lockingflange 17 of each metal sheet with the metal starting strip 27 followedby nailing the upper longitudinal edge of the metal sheets to theroofing substructure as clearly shown in FIGS. 1 and 2 of the drawings.

Succeeding courses 10b, 100, etc. of the roofing structure (that is, thesecond, third, etc. courses from below) are then applied to the roofingsubstructure by first securing the flashing pans 22 required for eachcourse to the substructure at appropriate intervals as previouslydescribed, followed by applying the shingle-like metal sheets 11 of thatcourse. As noted, one of the flashing pans 22 underlies each of the buttjoints of the adjoining metal sheets 11 in each course, the downwardlyturned locking flange 23 of the flashing pan 22 and the lower lockingflange 17 of the overlying metal sheets 11 overlapping and interlockingwith the upper locking flange of the metal sheet 11 positioned directlytherehelow as shown best in FIGS. 1 and 7. The metal sheets in adjacentcourses (for example, course 10a and 10b, 10b and 10c, etc.) should beapplied so that the butt joints of adjoining metal sheets 11 of onecourse do not coincide with the butt joints of adjoining sheets 11 ofthe adjacent course. In this manner the metal sheets 11 and theunderlying flashing pans 22 are applied to the roofing substructure in aplurality of vertically overlapping horizontal rows that, except for thejunctions of two pitched roof: sections hereinafter described,completely cover the roof with a weather-tight outer sheath of sheetmetal.

The trough-like junction formed where two pitched roof sections cometogether is made weather-tight by trimming the longitudinal edges of themetal sheets 11 so that they lap approximately five inches over the sideedges of the previously placed V-shaped metal flashing or valley strip29 as clearly shown in FIG. 1. An alternate method for making thetrough-like function weathertight is to incorporate folds 30 along thesides of the V-shaped metal flashing strip 29 in which folds 30 areengaged corresponding folds formed along the side edges of the metalsheets 11 as shown in FIG. 8. In like manner where two sections ofpitched roof come together to form a ridge-like juncture as shown inFIG. 2 the juncture is made weather-tight by trimming the longitudinaledges of the metal sheets to conform to the ridge line, followed byapplying sheet metal ridge cover members 31 over the joint to form aweather-tight assembly. As

shown in FIG. 9, the metal ridge cover members 31 are I advantageouslyprovided with downwardly turned locking flanges 32 at the lower endsthereof and with upwardly turned locking flanges 33 at the upper endsthereof which interlock with the corresponding locking flanges ofadjoining ridge cover members in the manner known in the art.

The improved roofing construction of our invention is characterized inthat each of the end edges 20 of each metal sheet 11 is located at thebottom of one of the vertically disposed depressed grooves 19 formed inthe metal sheet so that the edges of abutting metal sheets lie in closeproximity to the underlying roofing substructure. Moreover, thedepressed grooves 19 at the end edges of each metal sheet 11 strengthenand stiffen the metal sheet so that the ends of the sheet will not howupwardly when subjected to high winds or other external forces. Inaddition, the upwardly turned water seal lip members 24 formed along thevertical edges of each flashing pan 22 prevent the water collected bythe pan from flowing anywhere except downwardly on to the upper surfaceof the metal sheet 11 disposed directly therebelow. Moreover, theupwardly turned water seal lip members 24 serve to support the abuttingmetal sheets 11 disposed directly thereabove and thereby strengthen andstiffen the roofing structure of which these components are a part.

From the foregoing description of our new roofing construction it willbe seen that we have made an important contribution to the art to whichour invention relates.

We claim:

1. In a metal roofing construction in which a plurality of verticallyoverlapping horizontal courses of shingle-like metal sheets are securedto a planar roofing substructure, each course being formed from ahorizontal row of said metal sheets that overlap and interlock with themetal sheets of the course disposed directly therebelow, adjoining metalsheets in each course being provided with a metal flashing .panpositioned beneath the adjacent end edges of said adjoining metalsheets, each shingle-like metal sheet having an upwardly turned upperlocking flange adjacent to but spaced slightly below the upperlongitudinal edge of the metal sheet and with a downwardly turned lowerlocking flange adjacent the lower longitudinal edge of said metal sheet,the lower locking flanges of the metal sheets of one course of saidsheets engaging the upper locking flanges of the metal sheets of thecourse of said sheets positioned therebelow, each shinglelike metalsheet having at least two vertically disposed depressed groovesextending from a point slightly above the lower locking flange to apoint slightly below the upper locking flange of the metal sheet, one ofsaid vertically disposed depressed grooves being positioned at each endof the metal sheet with the end edge of metal sheet located at thebottom of said groove so that both end edges of each metal sheet lie inclose proximity to the underlying planar roofing substructure, eachflashing pan having a downwardly turned locking flange at the lower edgethereof and upwardly turned water seal lip members extending along eachvertical side edge of the flashing pan, said downwardly turned lockingflange of the flashing pan engaging the upwardly turned upper lockingflange of the metal sheet disposed directly therebelow, and the lowerend of each water seal lip member terminating at a point located abovethe locking flange of said flashing pan a distance equal to at leastone-half but not more than the full distance that the upper lockingflange of each metal sheet is spaced below the upper edge of said metalsheet.

2. The roofing construction according to claim 1 in which the upwardlyturned water seal li-p members of the flashing pans contact and supportthe undersurface of the shingle-like metal sheets disposed thereover.

References Cited UNITED STATES PATENTS 626,006 5/1899 Heidt 525311,111,674 9/1914 Pruitt 52-529 2,178,357 10/1939 Hoess 52-530 3,164,9291/1965 Boddie 52533 HENRY C. SUTHERLAND, Primary Examiner.

